US6477517B1 - Method of knowledge-based engineering design of an instrument panel - Google Patents

Abstract

A method of knowledge-based engineering design of an instrument panel for a vehicle includes the steps of defining a parameter of the instrument panel using a knowledge-based engineering library stored in a memory of a computer system, generating a model of the instrument panel based on the parameter and analyzing the model of the instrument panel. The method also includes the steps of comparing a result of the analysis of the model of the instrument panel to a predetermined criteria from the knowledge-based engineering library, and varying the parameter so that the model of the instrument panel meets the predetermined criteria.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to computer-aided design of vehicles and, more specifically, to a method of knowledge-based engineering design of an instrument panel for a vehicle.

2. Description of the Related Art

Vehicle design, and in particular automotive vehicle design, has advanced to a state in which computer-aided design techniques are frequently incorporated in the development of a new vehicle. Computer-aided design is especially beneficial in the design and packaging of the various systems incorporated within a vehicle, to maximize design and functional capabilities of the vehicle systems. One example of a vehicle system is an instrument panel. The instrument panel is positioned between a side structure of the vehicle to provide structural reinforcement for a vehicle body. The instrument panel also provides an attachment surface for various vehicle components such as an audio component, an inflatable restraint system, or a heating, ventilation and air conditioning (HVAC) system.

One aspect of the design task for a vehicle system, such as the instrument panel, is to ensure that the design of the vehicle system is spatially compatible with a particular environment. Another aspect of the design task is to ensure that the design complies with predetermined functional criteria, including performance and durability requirements. In the past, various methods have been utilized to determine whether a proposed design meets such predetermined criteria. For example, a proposed design may be analyzed in two dimensions, which requires many iterations of a drawing. A three-dimensional model may also be constructed to obtain a better perspective of the design. The three-dimensional model may further be subjected to testing to determine whether it complies with performance and durability criteria. This design method is time consuming and expensive.

It is also known that knowledge-based design methods are being utilized in designing a vehicle system. The knowledge-based design method provides advice to a user based on knowledge, guidelines and lessons learned from previous designs, and engineering and manufacturing experience. Advantageously, a knowledge-based design technique maximizes the incorporation of knowledge on the design of a vehicle system while developing a new vehicle system in a minimal period of time. An example of a knowledge-based design technique is disclosed in U.S. Pat. No. 5,799,293 to Kaepp, entitled “Method For Optimizing The Design Of A Product Using Knowledge Based Engineering Techniques”, the disclosure of which is hereby incorporated by reference.

It is also known to use a computer-aided design technique to design a vehicle system. An example of a computer aided design technique is disclosed in U.S. patent application, Ser. No. 08/984,806, entitled “Method and System For Vehicle Design Using Occupant Reach Zones”, the disclosure of which is also hereby incorporated by reference.

It is further known to use a parametric design technique to design a vehicle system. An example of a parametric design technique is disclosed in U.S. patent application, Ser. No. 09/385,739, entitled “Method of Parametric Design of an Instrument Panel Support Structure”, the disclosure of which is hereby incorporated by reference.

While the above design techniques work they do not integrate the available knowledge-based engineering design and analysis tools into a single user interface for the design of a complex system. Therefore, there is a need in the art to provide a method for designing an instrument panel for a vehicle using an integrated knowledge based engineering design technique, to reduce development time, and cost.

SUMMARY OF THE INVENTION

Accordingly, the present invention is a method of knowledge-based engineering design of an instrument panel for a vehicle. The method includes the steps of defining a parameter of the instrument panel using a knowledge-based engineering library stored in a memory of a computer system, generating a model of the instrument panel based on the parameter and analyzing the model of the instrument panel. The method also includes the steps of comparing a result of the analysis of the model of the instrument panel to a predetermined criteria from the knowledge-based engineering library, and varying the parameter so that the model of the instrument panel meets the predetermined criteria.

One advantage of the present invention is that an improved method of knowledge-based engineering design of an instrument panel for a vehicle is provided that considerably reduces design time and related expenses. Another advantage of the present invention is that a method of knowledge-based engineering design is provided that utilizes parametric automated design in light of predetermined engineering and manufacturing criteria. Yet another advantage of the present invention is that a method of knowledge-based engineering design of an instrument panel is provided that allows analysis of vehicle packaging feasibility early in the design process. Still another advantage of the present invention is that a method of knowledge-based engineering design of an instrument panel is provided which supports computer-aided engineering analysis (CAE) and rapid prototyping. A further advantage of the present invention is that a method of knowledge-based engineering design of an instrument panel is provided that enhances flexibility in design, while still meeting vehicle timing considerations. Still a further advantage of the present invention is that a method of knowledge-based engineering design is provided that utilizes knowledge, guidelines and lessons learned from design, engineering and manufacturing experience to design an instrument panel to improve the quality, reduce development time and reduce the cost of an instrument panel.

Other objects, features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a system which may be utilized with a method of knowledge-based engineering design of an instrument panel for a vehicle, according to the present invention.

FIG. 2 is a plan view of an instrument panel for a vehicle, according to the present invention.

FIG. 3 is a perspective view of an instrument panel support structure for the instrument panel of FIG.2.

FIG. 4 is a flowchart of a method of knowledge-based engineering design of an instrument panel, according to the present invention.

FIGS. 5,6,7,8,9a,9b,9c,10,11,12 and13 are flowcharts of another embodiment of a method of knowledge-based engineering design of an instrument panel, according to the present invention.

FIG. 14 is a view of a system for designing the instrument panel, according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Vehicle design, and in particular the design of an instrument panel50 (FIG. 2) on a vehicle, is achieved according to the present invention with a generic, parametric driven design method. Advantageously, this method allows flexibility in vehicle design and engineering analysis of the design in a fraction of the time required using conventional design methods, since the design is automatically evaluated against rules in the knowledge base. Various computer-based tools are integrated into a single user interface to achieve this enormous time and expense savings, including solid modeling, parametric design, automated studies and a knowledge-based engineering library.

Referring to the drawings and in particular FIG. 1, thetools10 used by a method for designing ainstrument panel50, according to the present invention, are illustrated graphically. Thetools10 include a knowledge-basedengineering library12 stored on an electronic storage device (not shown) The knowledge-basedengineering library12 includes design, engineering, and assembly rules for aninstrument panel50. In this example, the knowledge-basedengineering library12 is a database of sublibraries containing an electronic representation of various expert's knowledge of information relevant to the design of theinstrument panel50. For example, the knowledge-basedengineering library12 includes a component parts library containing a database of various types of component parts that may be supported by theinstrument panel50, in a manner to be described. Advantageously, the component part may be parametrically modelled.

The knowledge-basedengineering library12 also includes information in electronic form regarding various types of instrument panel architectures (to be described) that are available. Packaging studies incorporating these component parts on theinstrument panel50 can be done to assess many factors relating to the design of theinstrument panel50. The knowledge-basedengineering library12 still also includes a fastener library containing a database of various types of fasteners that may be utilized with theinstrument panel50. It should be appreciated that the fastener may be parametrically modeled. The knowledge-basedengineering library12 further includes a feature library containing information regarding different features available on theinstrument panel50. The feature may also be parametrically modeled. The knowledge-basedengineering library12 may also provide interactive access to other web-based libraries, in a manner to be described.

Thetools10 also include avehicle platform library14 stored on the electronic storage device. Thevehicle platform library14 is an electrical representation of a vehicle platform or a portion thereof. For example, thevehicle platform library14 may include a model of a particular vehicle body design, or a portion thereof. It should be appreciated that thevehicle platform library14 may be a sub-library within the knowledge-basedengineering library12.

Thetools10 may also include various design tools, shown generally at16, which can be used for thisdesign method20, in a manner to be described. Thesedesign tools16 may include solid modeling and parametric design techniques. Solid modeling, for example, takes electronically stored vehicle platform data from thevehicle platform library14 and standard component parts data from the knowledge-basedengineering library12 and builds complex geometry for part-to-part or full assembly interference checking. Several modeling programs are commercially available and generally known to those skilled in the art.

The parametric design technique is used in the electronic construction within acomputer system22 of a geometrically defined vehicle system, such as theinstrument panel50, or a component part therein. As a particular dimension or parameter is modified for a particular feature of theinstrument panel50 or component part therein, thecomputer system22 is instructed to regenerate a new geometric model. The knowledge-basedengineering library12 is used to control and limit the design process in accordance with predetermined design parameters, to be described.

Thetools10 also include various computer-aided engineering (CAE)analysis tools18. One example of an engineering analysis technique is a human factors study, to be described. Anotheranalysis tool18 is computational fluid dynamics (CFD), as is known in the art

Thetools10 further include thecomputer system22 as is known in the art to implement a method andsystem20 for designing theinstrument panel50. Thecomputer system22 includes a processor and amemory24a, which can provide a display and animation of a system, such as theinstrument panel50, on a display device such as a video terminal24b. Parametric selection and control for the design can be achieved by auser26, via a user interactive device24c, such as a keyboard or a mouse. Theuser26 inputs a set of parameters and set of instructions into thecomputer system22 when prompted to do so by themethod20. The set of parameters and the set of instructions may be product specific, wherein other data and instructions non-specific to the product may already be stored in thecomputer system22.

One example of an input method is a pop-up window with all current parameters, including an on-line description for the parameter and a current value therefore. For example, parametric values may be chosen from a table within a two-dimensional mode, since some vehicle designers prefer to view an assembly in sections which can be laid out on a drawing.

Once thecomputer system22 receives the set of parameters and instructions from auser26, thecomputer system22 utilizes a method, discussed in detail subsequently, to determine whether requirements have been met.

Advantageously, the computer implemented method of knowledge-based engineering design of aninstrument panel50 combines all of the foregoing to provide an efficient, flexible, andrapid design28. Further, an instrument panel design is an output of themethod20, and thedesign28 is available for further analysis and study.

Referring to FIGS. 2 and 3, theinstrument panel50, according to the present invention, is to illustrated for a vehicle (not shown), and in particular an automotive vehicle. The vehicle includes a vehicle body (not shown) which serves as a frame for the vehicle, as is known in the art. The vehicle body includes two side structures (not shown), which are referred to in the art as A-pillars. The vehicle body also includes a front structure (not shown), known as the dash panel, that forms a generally planar surface extending between the side structures. It should be appreciated that the vehicle front structures and side structure define an interior space of the vehicle referred to as the occupant compartment. The vehicle body includes a generally planar member (not shown) positioned between the side structures and extending from an upper edge of the dash panel into the occupant compartment, referred to in the art as a cowl. Theinstrument panel50 is positioned between the side structures and rearward of the cowl, and attached to the vehicle in a manner to be described. Advantageously, theinstrument panel50 provides an attachment surface for components typically disposed therein, such as aninstrument cluster52, aradio54 or the like.

Theinstrument panel50 also includes an outer skin56 covering an instrumentpanel support structure100. Preferably, the outer skin56 is made from a plastic material. The outer skin56 may include a rigid foam material covering the plastic material to give the outer skin56 a soft appearance and feel.

The instrumentpanel support structure100 provides a frame for theinstrument panel50 and the components contained therein. The instrumentpanel support structure100 includes a longitudinally extending beam102, referred to in the art as a cross-car support beam. The beam102 provides rigidity and support to the vehicle body and an attachment surface for various components, in a manner to be described. The beam102 may be divided into adriver side portion104 on one end, and apassenger side portion106 on another end, and a central portion108 between thepassenger side portion106 and thedriver side portion104.

In this example, the shape of the beam102 is parametrically determined in light of various input parameters that associatively link a parameter to a coordinate in space. For example, an input parameter is a dimensional coordinate for the attachment locations of the beam102 relative to the vehicle body. Another input parameter is the axis of the beam102. Still another is the relative shape of the vehicle body and related components.

The beam102 includes anend bracket112 for attaching the beam102 to part of the vehicle body, such as the cowl, in this example. Theend bracket110 is generally planar, and is joined onto an end of the beam102, using a suitable means such as welding. Preferably, there is a left end bracket110A located on the end of thedriver side portion104 of the beam102 and a right end bracket110B located on the end of thepassenger side portion106 of the beam102. The left and right end brackets110A,110B may each include anaperture112 for receiving a fastener (not shown), such as a bolt, to secure the beam102 to the cowl.

In this example, the left or right end rackets110A,110B have an general “L” shape. It should be appreciated that the left end bracket110A may have a different shape than the right end bracket110B, depending on the design of the beam102. Advantageously, the shape of the right or left end bracket110A,110B is determined in light of mating associative parts defining the attachment location of the beam102 relative to the vehicle body.

The instrumentpanel support structure100 also includes anupper attachment bracket114, also referred to as a cowl top bracket, for attaching the beam102 to the cowl. Theupper attachment bracket114 is generally planar and extends radially from the beam102 a sufficient distance to secure the instrumentpanel support structure100 to the cowl. Theupper attachment bracket114 may include aflange116 extending from a side edge of theupper attachment bracket114 to provide additional strength to theupper attachment bracket114.

In this example, theupper attachment bracket114 has a general “J” shape. Advantageously, the shape of theupper attachment bracket114 may be parametrically determined using an input parameter, such as a coordinate point in 3-dimensional space representing an attachment location of the cowl to the vehicle body structure. Another end of theupper attachment bracket114 is associatively referenced to another input parameter, such as a centerline for the beam102.

An end of theupper attachment bracket114 is secured to the beam102 by a suitable joining means such as welding. Another end of theupper attachment bracket114 is secured to the cowl by a suitable means such as a fastener (not shown). Theupper attachment bracket114 includes an aperture (not shown) for receiving the fastener to secure theupper attachment bracket114 to the cowl.

The instrumentpanel support structure100 also includes a steeringcolumn support bracket120 for supporting the steering column (not shown), as is known in the art. The steeringcolumn support bracket120 is a generally planar member extending radially from the beam102 a sufficient amount in a rearward vehicle direction. In this example, the steeringcolumn support bracket120 has a flange122 extending along a side edge to provide additional strength, so that the steeringcolumn support bracket120 has a generally “U”-shape.

The shape of the steeringcolumn support bracket120 may be determined in light of a mating associated part, such as the design of the beam102 and a three dimensional coordinate system representing a location for the steering column. An edge of the steeringcolumn support bracket120 is attached to the beam102 by a suitable joining means, such as welding. The steeringcolumn support bracket120 may include a suitable means such as a fastener124 to secure the steering column to the instrumentpanel support structure100. It should be appreciated that, in this example, there are two steeringcolumn support brackets120 positioned parallel each other.

The instrumentpanel support structure100 also includes a knee bolster126. The knee bolster126 absorbs energy of a portion of an occupant's body (not shown), such as a knee, under certain conditions. One example of a condition is the movement of an unrestrained occupant as a result of an impact with another object (not shown). In this example, there are two knee bolsters126, a driver side knee bolster128 and a passenger side knee bolster130.

The driver side knee bolster128 is a generally planar member that is attached to thedriver side portion104 of the instrumentpanel support structure100 by a plurality ofattachment brackets132,136,138. The location in driver side space of the knee bolster128 is driven by information such as, input from adesign tool16 such as a knee bolster study.

An upper driver side knee bolsterattachment bracket132 interconnects an upper edge of the driver side knee bolster128 with the beam102. Advantageously, the upper driver side knee bolsterattachment bracket132 absorbs energy resulting from an impact with an object. The upper driver side knee bolsterattachment bracket132 is a generally planar member having a flange extending along an edge to provide additional structural strength. The upper driver side knee bolsterattachment bracket132 has a generally J-shape. Advantageously, the shape of the upper driver side knee bolsterattachment bracket132 is determined in light of mating associative parts, including the driver side knee bolster128, and the diameter of the beam102, as well as an input from adesign tool16 such as the knee bolster study.

Preferably, one end of the upper driver side knee bolsterattachment bracket132 is secured to the beam102 using a suitable joining means such as welding. Another end is secured to the driver side knee bolster128 using a suitable means such as a fastener (not shown). It should be appreciated that, in this example, there are two upper driver side knee bolsterattachment brackets132.

An outer driver side knee bolsterattachment bracket136 secures an outer edge of the driver side knee bolster128 to the vehicle body. The outer driver side knee bolsterattachment bracket136 is generally planar. In this example, the outside driver side knee bolsterattachment bracket136 has a generally “Z”-shape. Advantageously, the shape of the outer driver side knee bolsterattachment bracket136 is determined from information regarding the position and shape of the driver side knee bolster128 relative to the vehicle body. Preferably, one end of the outer driver side knee bolsterattachment bracket136 is secured to the driver side knee bolster128 by a suitable means such as welding. Another end is also secured to the vehicle body by a suitable means such as a fastener (not shown).

An inner driver side knee bolsterattachment bracket138 secures an inner edge of the driver side knee bolster128 with acenter support bracket150, to be described. The inner driver side knee bolsterattachment bracket138 is generally planar. In this example, the inner driver side knee bolsterattachment bracket138 has a generally “L”-shape. Advantageously, the shape of the inner driver side knee bolsterattachment bracket138 is determined in light of information regarding its associativity to the position and shape of the driver side knee bolster128 and acenter support bracket150 to be described. Therefore, the design can change the shape of the inner knee driver side bolsterattachment bracket138 from a generally “L” to a “Z”. Preferably, one end of the inner driver side knee bolsterattachment bracket138 is secured to the driver side knee bolster128 by a suitable means such as welding. Another end is also secured to the vehicle body by a suitable means such as a fastener (not shown).

The passenger side knee bolster130 is a generally rectangular member extending from thepassenger side portion106 of the beam102. In this example, the passenger side knee bolster130 has acentral cavity140 for receiving a glove box member (not shown), as is known in the art. In this example, the location of the passenger side knee bolster130 is driven by information from thedesign tool16, such as the knee bolster study, and associatively referenced to the beam102.

The passenger side knee bolster130 is secured to the beam102 by an upper passenger side knee bolsterattachment bracket142. The upper passenger side knee bolsterattachment bracket142 interconnects an upper edge of the passenger side knee bolster130 with thepassenger side portion106 of the beam102. Advantageously, the upper passenger side knee bolsterattachment bracket142 also absorbs energy resulting from an impact with an object.

The upper passenger side knee bolsterattachment bracket142 is a generally planar member having aflange144 extending along an edge to provide additional structural strength. The upper passenger side knee bolsterattachment bracket142 has a generally J-shape. In this example, the shape of the upper passenger side knee bolsterattachment bracket142 is determined in light of information regarding the position and orientation of mating surfaces of the beam102 and the passenger side knee bolster130, and an input from adesign tool16 such as the knee bolster study.

Preferably, one end of the upper passenger side knee bolsterattachment bracket142 is secured to thepassenger side portion106 of the beam102 using a suitable means such as welding. Another end of theattachment bracket142 is secured to the passenger side knee bolster130 using a suitable means such as a fastener (not shown). It should be appreciated that, in this example, there are two upper passenger side knee bolsterattachment brackets142.

An outer passenger side knee bolsterattachment bracket146 secures an outer edge of the passenger side knee bolster130 with the vehicle body. The outer passenger side knee bolsterattachment bracket146 and outer driver side knee bolsterattachment bracket136 may have the same shape. The outer passenger side knee bolsterattachment bracket146 is generally planar. In this example, the outer passenger side knee bolsterattachment bracket146 has a generally “Z”-shape. Advantageously, the shape of the outer passenger side knee bolsterattachment bracket146 is associated with the passenger side knee bolster130 and the vehicle body. Preferably, one end of the outer passenger side knee bolsterattachment bracket146 is secured to the passenger side knee bolster130 by a suitable means such as welding. Another end of theattachment bracket146 is also secured to the vehicle body by a suitable means such as a fastener.

An inner passenger side knee bolsterattachment bracket148 secures an inner edge of the passenger side knee bolster130 with thecenter support bracket150. The inner passenger side knee bolsterattachment bracket148 is generally planar. In this example, the inner passenger side knee bolsterattachment bracket148 has a general “L”-shape. Advantageously, the shape of the inner passenger side knee bolsterattachment bracket148 is determined in a manner similar to the inner driver side knee bolsterattachment bracket142, previously described. Preferably, one end of the outer passenger side knee bolsterattachment bracket146 is secured to the passenger side knee bolster130 by a suitable means such as welding. Another end of the inner passenger side knee bolsterattachment bracket148 is also secured to the vehicle body by a suitable means such as a fastener (not shown).

The instrumentpanel support structure100 includes acenter support bracket150 extending between a central portion108 of the beam102 and a portion of the vehicle body such as a floor (not shown). Thecenter support bracket150 provides a mounting surface for a center component (not shown) disposed within the instrument panel, such as an audio component or a heating, ventilation and air conditioning HVAC controller, as is known in the art.

Thecenter support bracket150 is generally planar, and extends longitudinally a sufficient distance to provide support to components disposed therein. In this example, a side edge has a flange extending therealong to enhance the structural integrity of thecenter support bracket150. An upper end of thecenter support bracket150 is secured to the beam102 by a suitable means such as welding. A lower end of thecenter support bracket150 is secured to the vehicle body, by a suitable means such as a fastener (not shown). In this example, there are twocenter support brackets150 positioned a predetermined distance apart from each other.

Referring to FIG. 4, a flowchart of a method of knowledge-based engineering design of theinstrument panel50, according to the present invention, is illustrated. Advantageously, the method embeds knowledge, guidelines and lessons learned from design, engineering and manufacturing experts to interactively develop a new instrument panel design. The methodology begins inbubble200, when it is called for by theuser26. The methodology advances to block202 and defines parameters of theinstrument panel50 for a particular vehicle type. In this example, the parameters are defined in a product definition module, to be described. For example, a parameter from thevehicle platform library14 includes information in electronic form regarding the vehicle environment, such as interior size, as well as a vehicle body model. Another parameter from the knowledge-basedengineering library12 is information regarding vehicle systems, including a type of instrument panel and component parts disposed within theinstrument panel50.

Still another parameter is the shape of theinstrument panel50, as defined by coordinates in space that reference the general shape of theinstrument panel50 and position theinstrument panel50 with respect to the vehicle body. In particular, these coordinate points define specific reference points on the cross car support beam102 for determining the shape and attachment of the cross car support beam102 and other components or brackets that may be secured to the beam102 or a portion thereof. The methodology advances to block204.

Inblock204, the methodology electronically generates a preliminary model of theinstrument panel50 using the parameters fromblock202 and packages theinstrument panel50 in relation to the vehicle systems previously described. The model is generated using thedesign tool16 such as a computer aided design technique, as is known in the art. Preferably, the appropriate relationships between theinstrument panel50, vehicle body and other vehicle structures are automatically determined and based upon the information provided from the knowledge-basedengineering library12 and definition of theinstrument panel50.

It should be appreciated that packaging refers to an electronic representation of the dimensions of the system, device or component as it geometrically relates to a three-dimensional reference frame of the vehicle. These vehicle systems may include, but are not limited to theinstrument panel50, the dash panel, cowl side structure, instrumentpanel support structure100, and HVAC assembly (not shown). A vehicle system is intended to include any part of the vehicle which will interact with theinstrument panel50 either directly or indirectly.

The methodology advances to block206 and evaluates the preliminary instrument panel model using thedesign tool16 such as CAE or theanalysis tool18, such as a human factors study, or CFD. The methodology advances to block208 and determines if the preliminary model of the instrument panel design meets a predetermined criteria from the knowledge-basedengineering library12. An example of a predetermined human factors design criteria includes reach to theinstrument panel50, ergonomics or knee bolster position. An example of a predetermined performance criteria is a stress or vibration limit, as is known in the art.

If the preliminary design does not meet the predetermined criteria, the methodology advances to block210 and modifies a previously defined parameter and returns to block204, previously described. If the preliminary design does meet the predetermined criteria, the methodology advances to block212. Inblock212, theuser26 defines additional parameters of theinstrument panel50 using the knowledge-basedengineering library12, to generate a more detailed model of the instrument panel design. For example, the additional parameters may provide a more detailed representation of the surface of theinstrument panel50, and include features such as bosses, and fasteners.

The methodology advances to block214 and electronically generates a detailed model of the instrument panel design, as previously described. The methodology advances todiamond218 and determines if the detailed model meets a predetermined criteria such as a rule or guideline from the knowledge-basedengineering library12. An example of a predetermined criteria is a feature design guideline from a feature library, to be described. Another example of a predetermined criteria is the availability of a fastener from a fastener library, to be described. Still another example of a predetermined criteria is the shape of a radial edge from a tooling feasibility library, to be described.

If the predetermined criteria is not met, the methodology advances to block216 and modifies a defined parameter and returns to block212, previously described. If the predetermined criteria is met, the methodology advances to block220. Inblock220 the design is complete and the methodology ends.

Referring to FIGS. 5 through 13, a detailed example of another embodiment of the method of knowledge-based engineering design of theinstrument panel50 is illustrated. The methodology begins inbubble300, when it is called for by auser26. The methodology advances to302 and theuser26 selects a vehicle model from a database, such as thevehicle platform library14. The methodology advances to block304 and theuser26 selects a knowledge-based module for developing an instrument panel design. The knowledge-based module provides for the development of an aspect of the instrument panel design, in a manner to be described. It should be appreciated that the flexability of the method allows for additional knowledge-based modules to be included in the method. It should also be appreciated that the knowledge-based modules may be interactively accessed by theuser26 in a preferred order.

If theuser26 selects a product definition module, the methodology advances tocircle310, and continues to bubble312 shown in FIG.5. The methodology begins incircle312 and continues todiamond314. Indiamond314, the methodology determines if a model of an instrument panel design is already available. Preferably, the model includes coordinate points that reference the shape of theinstrument panel50. If a model of the instrument panel design is not available, the methodology advances to block316 and obtains the model of theinstrument panel50, such as from thevehicle platform library14 and continues todiamond318. If a model of theinstrument panel50 is available, the methodology advances todiamond318.

Indiamond318, the methodology determines if parameters, such as characteristics or attributes, have already been defined for the model of theinstrument panel50. The parameters influence design, engineering and manufacturing requirements of theinstrument panel50. An example of a parameter is the model year. Another example of a parameter is an anticipated production volume on a per year basis. Still another parameter is whether steering is on the left side or the right side. A further parameter is an anticipated date of first production.

If parameters have not been defined for the model, the methodology advances to block320. Inblock320, the methodology defines parameters for the model of the instrument panel design. For example, theuser26 interactively supplies the parameter to the method when asked to do so. The methodology advances to block322, to be described.

Referring back todiamond318, if the parameters have been defined, the methodology advances to block322. Inblock322, the methodology selects a parameter, such as a characteristic or attribute, of theinstrument panel50 from the knowledge-basedengineering library12. One characteristic of an instrument panel is a soft instrument panel. Another characteristic of instrument panel is a hard instrument panel. The methodology advances to block324.

Inblock324, the methodology selects a component part and its parameters to be included within the model from the knowledge-basedengineering library12. One example of a component part is the skin56 covering theinstrument panel50. Its attribute is the material type and characteristics substrate. Another example of a component part is the cross car support beam102 and its attribute is material type. Another example of a component part usually disposed within theinstrument panel50 include theradio54, airbag (not shown) or HVAC unit (not shown) as previously described. The methodology advances to block326 and returns to block304 in FIG.5.

Referring back to block304, if theuser26 selects a component part library module, the methodology advances tocircle350 and continues to bubble352 shown in FIG.7. The component part library is an electronic database within the knowledge-basedengineering library12 that contains information regarding particular component parts positioned within theinstrument panel50, for a packaging analysis of the instrument panel design. The methodology begins inbubble352 and advances to block354.

Inblock354, the methodology selects a particular component to be included in the model. An example of a component is theradio54, the HVAC unit, theinstrument cluster52 or the airbag. The methodology advances todiamond356 and determines if a model of the instrument panel design is already defined within the knowledge-basedengineering library12. If the model of the instrument panel design has not been defined, the methodology advances todiamond358 and theuser26 determines if another model should be selected. If another model should not be selected, the methodology advances to block360. Inblock360, only the selected component is available for further analysis by the method of instrument panel design. The methodology advances tocircle372 and returns to the entry point inblock304 of FIG.5. Returning todiamond358 if another model should be selected, the methodology advances to block362 and selects another parametric model. The methodology advances to block368, to be described.

Returning todiamond356, if the model of the instrument panel design has been defined, the methodology advances todiamond366. Indiamond366, theuser26 determines if the selected component part should be included in the defined model. If the selected component part should not be part of the defined model, the methodology advances to block364. Inblock364, the methodology does not use the selected model and advances todiamond358, previously described.

Returning todiamond366, if the selected component should be part of the defined model, the methodology advances to block368 and generates a model of the instrument panel design that includes the selected component parts. The methodology advances to block370 and verifies the position of the component part within the model. For example, the model may be compared to a predetermined design criteria set forth in the knowledge-basedengineering library112. The methodology advances tocircle372 and returns to the entry point fromblock304 in FIG.

Referring to block304, if a human factors module is selected, the methodology advances tocircle400 and continues to bubble402 in FIG.8. Advantageously, the human factors module is a human factors analysis that validates that the instrument panel design complies with packaging and ergonomic requirements. The methodology advances tobubble402 and continues to block404. Inblock404, the methodology selects a model of the instrument panel design for analysis. It should be appreciated that the model may be a parametric, ergonomic model superposed on the model of the instrument panel. In this example, the selected model is in a computer-aided design (CAD) format, as is known in the art. The methodology advances to block406.

Inblock406, the methodology selects a particular portion of theinstrument panel50 for analysis. An example of a portion of theinstrument panel50 is the knee bolster126. It should be appreciated that for a particular aspect of theinstrument panel50, a particular analysis may be performed. Thus, the human factors module will manage the model and select a necessary aspect of the selected application required in performing the analysis. The methodology advances to block408.

Inblock408, the methodology selects an analysis to be performed on the model from theanalysis tools18. An example of an analysis is a knee bolster study or reach study. It should be appreciated that the methodology may select one or more analyses to be performed either simultaneously or sequentially. The methodology advances to block410.

Inblock410, the methodology updates a parameter before conducting a human factor analysis. An example of a parameter is a seating reference point or a seat back angle. Advantageously, the parameters may be dynamically changed depending on which predetermined study was selected. The methodology advances todiamond412 and determines if the parameter is valid when compared to a predetermined design criteria from the knowledge-basedengineering library12. For example, the methodology may check if the parameter is outside a range specified for the parameter, and indicate a suggested range. The methodology advances todiamond414.

Indiamond414, the methodology compares the parameter to a knowledge-based engineering criteria or guideline contained within the knowledge-basedengineering library12 to determine if the parameter violates the predetermined criteria. If the parameter is in violation, the methodology returns to block410, previously described. If the parameter does not violate a guideline, the methodology advances to block416. Inblock416, the methodology regenerates the model to include the parameters modified inblock410. The methodology advances to block418 and selects a physical zone or portion of the model of the instrument panel design to be studied. Advantageously, theuser26 can superpose the current model on another model to visualize the result of the analysis. The methodology advances to block420.

Inblock420, the methodology saves the results of human factors model on the computer system1100 (FIG.14). Advantageously, the human factors model may be exported into another analysis, as is understood in the art. The methodology advances tobubble422 and returns to the entry point inblock304 in FIG.5.

Referring to block304 in FIG. 5, if a feature library module is selected by theuser26, the methodology advances to block450, and continues to bubble452 in FIG.9A. The feature library module constructs and places various types of detailed features on the surface of the model for the instrument panel design. It also provides for modifications to existing features. An example of a feature is a boss or a clip tower. Advantageously, the feature library contains information regarding the types of features, so that the design of the feature can be evaluated. Inbubble452, the methodology advances to block454. Inblock454, theuser26 selects a feature action, including whether to create, modify, copy, delete or evaluate a feature.

If theuser26 selects to create, modify or copy a feature, the methodology advances to block456 and continues to block458. Inblock458, theuser26 determines what type of feature is to be created, modified or copied. In this example, the options include a boss or a clip tower. It should be appreciated that the boss may include sub-features such as a boss, a hole, a counterbore, a material saver and a gusset. If theuser26 selects a boss to be created, modified or copied, the methodology advances to circle A shown at460 in FIG.9B and continues.

Referring to FIG. 9B, the methodology begins in circle A shown at460 to create, modify or copy a boss, depending on the selected action. The methodology advances to block462 and theuser26 selects characteristics of the boss. For example, a characteristic may be the type of surface, such as class A. Another characteristic is the material, such as ABS. Still another characteristic is a type of fastener, such as a screw. The methodology advances to block464 and theuser26 selects a type of boss to be created, modified or copied. For example, if a boss including a hole with a counterbore is selected, the methodology advances to block466 and theuser26 enters information regarding parameters of the counterbore, such as size and shape. For example, the counterbore may have either a cylindrical or a hexagonal shape. The diameter, depth and draft of the counterbore may also be entered.

The methodology advances todiamond468 and theuser26 selects whether to keep the counterbore. If the counterbore should not be kept the methodology advances tobubble470 and returns to the entry point from circle A and continues. Returning todiamond468, if the counterbore should be kept, the methodology advances to block470. Inblock470, the methodology constructs a parametric model of the instrument panel design including the boss hole with the specified parameters for the counterbore. The methodology advances tobubble480 and returns to the entry point from circle A.

Returning to block472, if a boss without gussets is selected by theuser26, the methodology advances to block480 and returns to the entry point from circle A and continues.

Returning to block464, if a boss with gusset is selected, the methodology advances to block474. Inblock474, theuser26 provides information regarding parameters of the gusset, such as size, shape and quantity. In particular, theuser26 may specify land, draft, thickness, angle, shape and location of the gusset from the top of the boss.

The methodology advances todiamond476 and determines if the boss with gusset should be kept in the model. If the boss with gusset should not be kept, the methodology advances tobubble480 and returns to the entry point from circle A. If the boss with gusset should be kept, the methodology advances to block478 and constructs a model of the instrument panel design including the boss with a gusset using the specified parameters for the boss and gusset. The methodology advances tobubble480 and returns to the entry point from circle A.

Returning to block458 of FIG. 9A, if theuser26 selects a clip tower feature, the methodology advances to circle B in FIG.9C and continues. In circle B, shown at458, the method constructs a clip tower. The methodology advances to block484 and theuser26 selects a type of clip tower to construct, such as with a guide or without guide. If a clip tower without a guide is selected, the methodology advances to block486. Inblock486, theuser26 enters information regarding a parameter that defines the clip tower. For example, the parameters may define the material, height, width, length, thickness, draft, cut, chamfers and ribs. The methodology advances tobubble494 and returns to the entry point from circle B.

Returning to block484, if a clip tower with guides is selected by theuser26, the methodology advances to block488. Inblock488, theuser26 enters information regarding parameters defining the clip tower, as previously described, as well as information regarding the shape and location of a guide. The methodology advances todiamond490 and theuser26 selects whether to include the guides in the model of the instrument panel design. If the guides should not be included, the methodology advances tobubble494 and returns to the entry point from circle B.

Returning todiamond490, if the guides should be included, the methodology advances to block492 and generates a model of the instrument design panel that includes a clip tower with guides according to the entered parameters. The methodology advances tobubble494 and returns to entry point from circle B.

Returning to FIG. 9A, the methodology advances to block500 from circle A or circle B. Inblock500, the feature is compared to a predetermined criteria such as a guideline or rule contained within the knowledge-base engineering library12 for an initial determination of whether the feature violates the predetermined criteria. An example of a predetermined criteria is a component design guideline, or an injection molding guideline. The methodology advances todiamond502 and determines from the comparison inblock500 if the feature violates the predetermined criteria. If the predetermined criteria is violated, the methodology advances to block504. Inblock504, the violation is displayed on a video terminal24b. The methodology advances tobubble506 and returns to block304 in FIG.5.

Referring back todiamond502, if the guideline is not violated, the methodology advances tobubble506 and returns to inblock304 in FIG.5.

Returning back to block454, if theuser26 selects a delete feature action, the methodology advances to block508. Inblock508, a type of feature to be deleted is selected and the methodology continues to block510. Inblock510, the feature is deleted from the model, and the model is regenerated without the feature. The methodology advances tobubble506 and returns to block304 in FIG.5.

Returning to block454, if an evaluate feature is selected, the methodology advances todiamond514 and continues todiamond516. Indiamond516, theuser26 selects a means of evaluating the feature. For example, if a single feature is selected, the methodology advances to block518 and evaluates the selected feature by comparing the selected feature to a predetermined criteria from the knowledge-basedengineering library12 for any violations. The methodology advances to block520 and displays the results of the evaluation on the video terminal24b. The methodology returns to block454 previously described.

Returning todiamond516, if theuser26 selects multiple features to evaluate, the methodology advances to block522 and evaluates all features by comparing all the features to a predetermined criteria from the knowledge-basedengineering library12 for any violations. The methodology advances to block524 and displays the results of the evaluation on the video terminal24b. The methodology returns to block454 previously described.

Returning todiamond516, if a clearance check is selected, the methodology advances to block526. Inblock526, the methodology determines if a clearance between two components is within a predetermined range from the knowledge-basedengineering library12. The methodology advances to block528 and displays any violations on the video terminal24b. The methodology advances tobubble506 and returns to block304 in FIG.5.

Returning to block304 of FIG. 5, if a tooling feasibility module is selected, the methodology advancesblock600. Inblock600, the methodology advances to bubble602 shown in FIG.10. Advantageously, the tooling feasibility module evaluates individual portions of theinstrument panel50 for various conditions that may affect how a tool is built to fabricate theinstrument panel50. An example of a condition is a die lock or undercut. Another example is a sharp edge. Still another condition is an inadequate draft. Advantageously, if a certain tooling condition is identified early in the design process and avoided, time, effort and cost can be saved.

The methodology continues to block604 and selects a component part of theinstrument panel50 to evaluate. The methodology advances to block606. Inblock606, theuser26 selects a type of tooling feasibility evaluation to perform, such as a die lock check, sharp-edges check, or inadequate draft angle check. The methodology advances to block608.

Inblock608, the component part is compared to a predetermined tooling rule stored in the knowledge-basedengineering library12. For example, the knowledge-basedengineering library12 may contain a rule that a draft angle be a minimum angle of 0.50 degrees to obtain a sufficient draft. It should be appreciated that a portion of the component part may be evaluated or the entire component part.

The methodology advances todiamond610 and determines from the comparison inblock608 if the rule from the knowledge-basedengineering library12 has been met. If the rule has not been met, the methodology advances todiamond612 and theuser26 determines if the model of theinstrument panel50 should be updated. If the model should be updated the methodology advances to block616 and modifies the model. The methodology advances to block616 and regenerates the model of theinstrument panel50. The methodology returns to block604 previously described.

Returning todiamond612, if the model should not be updated, the methodology advances tobubble618 and returns to block304 in FIG.5. Returning todiamond610, if the rule is not met, the methodology advances tobubble618 and returns to block304 in FIG.5.

Returning back to block304 of FIG. 5, if a fastener library module is selected, the methodology advances to block628 and advances to bubble630 shown in FIG.11. Advantageously, the fastener library is a database of available fasteners maintained in the knowledge-basedengineering library12. The methodology advances todiamond632 and theuser26 selects a type of fastener. One example of a fastener is a screw. Another example of a fastener is a nut or clip. If a screw is selected the methodology advances to block634. The methodology advances to block636 and selects a particular screw from the fastener library database. Advantageously, the database can be sorted by a physical characteristic such as class of screw, or size or length of screw.

The methodology advances to block638 and informs theuser26 of a guideline or rule from the knowledge-based library associated with usage of the type of screw selected on the video terminal24b. The methodology advances to block644, to be described. Returning todiamond632, if a fastener type, such as a nut or clip, is selected, the methodology advances to block640 and continues to block642. In block642, theuser26 selects a particular nut or clip from the fastener library database within the knowledge-basedlibrary12. Advantageously, the database is sorted by a characteristic such as class of nut or type of clip. The methodology advances to block644, and theuser26 selects a number of copies of the fastener to be included in the model of the instrument panel design.

The methodology advances todiamond646 and theuser26 selects whether to include the fastener as part of the model of the instrument panel design. If the fastener should be included as part of the model, the methodology advances to block648. Inblock648, the methodology regenerates the model with the fastener included therein. The methodology advances tobubble650 and returns to block304 in FIG.5. Returning todiamond646, if the fastener should not be included with the model of the instrument panel design, the methodology advances tobubble650 and returns to block304 in FIG.5.

Returning to block304 in FIG. 5, if a fastener commonization module is selected, the methodology advances to circle658, and advances to bubble660 shown in FIG.12. Advantageously, the fastener commonization module checks the model and looks for standard fasteners to improve the cost and assembly of theinstrument panel50. The methodology advances to block662 and selects a model of an instrument panel design to check for fastener commonization. The methodology advances to block664 and compares the fasteners used in the model to a predetermined list of standard fasteners maintained in the knowledge-based engineering library.12. For example, the predetermined list of standard fasteners may be a list of fasteners used in a particular assembly plant. The methodology advances to block666 and displays a list of standard fasteners identified in the model on a terminal24b. Advantageously, the quantity and a part identification number can be included as part of the displayed information. The methodology advances tocircle668 and returns to block304 in FIG.5.

Returning to block304 of FIG. 5, if theuser26 selects a knowledge-based library module, the methodology advances block678 and advances to bubble680 shown in FIG.13. The methodology begins inbubble680 and advances to block682. Inblock682, theuser26 selects a reference library from the knowledge-basedengineering library12. It should be appreciated that the reference library may be contained within the knowledge-based engineering library, or may be an external web-based library accessible through the knowledge-basedengineering library12. For example, the reference library may be related to theinstrument panel50, such as a library containing information regarding design guidelines and requirements. Still another reference library may contain benchmark information. A further reference library may contain federal guidelines. The methodology advances tobubble684 and returns to block304 in FIG.5.

Returning to block304 of FIG. 5, if the model of the instrument panel design is finished, the methodology advances tobubble1000 and ends.

Referring to FIG. 14, arepresentative hardware system1100 for implementing the method for knowledge-based engineering design of aninstrument panel50, according to the present invention, is illustrated. Thehardware system1100 includes aprocessing unit1102 connected to a user interface which may include a video terminal1104, akeyboard1106, a pointing device, such as amouse1108, and the like. Theprocessing unit1102 preferably includes a central processing unit, a memory, and stored instructions which implement the method for designing theinstrument panel50, according to the present invention. The stored instructions may be stored within theprocessing unit1102 in the memory, or in any non-volatile storage such as magnetic or optical media, EPROM, EEPROM, or the like. Alternatively, instructions may be loaded from removalmagnetic media1100, such as a removal disk, sometimes called a floppy disk, optical media1112, or the like. In a preferred embodiment, thehardware system1100 includes a general-purpose computer program to implement the functions illustrated and described with reference to FIGS. 1-13. Of course, ahardware system1100, according to the present invention, could also be embodied with a dedicated device which includes various combinations of hardware and software.

The preferred embodiment may also include aprinter1114 connected to theprocessing unit1102, as well as a network connection for accessing a local server, an intranet, and the Internet. Preferably, solid modeling software, parametric design software, surface rendering software, animation software, and the like are used for developing thehardware system1100, according to the present invention.

The present invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically described.

Claims (23)

What is claimed is:

1. A method of knowledge-based engineering design of an instrument panel for a vehicle, the method comprising the steps of:

defining a parameter of the instrument panel using a knowledge-based engineering library stored in a memory of a computer system;

generating a model of the instrument panel based on the parameter;

analyzing the model of the instrument panel;

comparing a result of the analysis of the model of the instrument panel to a predetermined criteria from the knowledge-based library; and

varying the parameter so that the model of the instrument panel meets the predetermined criteria.

2. A method as set forth inclaim 1 wherein the method includes the steps of defining an input parameter for the model of the instrument panel using the knowledge-based engineering library, and generating a model of the HVAC air-handling assembly based upon the input parameter.

3. A method as set forth inclaim 2 wherein the method includes the steps of comparing the model of the instrument panel to a predetermined initial criteria from the knowledge-based engineering library, and varying the input parameter so that the model of the instrument panel meets the predetermined initial criteria.

4. A method as set forth inclaim 3 wherein the predetermined criteria is a human factors design rule from the knowledge-based engineering library.

5. A method as set forth inclaim 2 wherein the method includes the steps of comparing an engineering performance analysis of the model of the instrument panel to a predetermined performance criteria from the knowledge-based engineering library, and varying the input parameter so that the model of the instrument panel meets the predetermined performance criteria.

6. A method as set forth inclaim 1 wherein the method includes the steps of defining a second parameter for the model of the instrument panel using the knowledge-based engineering library, and regenerating the model of the instrument panel using the second parameter.

7. A method as set forth inclaim 6 wherein the second parameter is a feature defining a surface of the instrument panel from a feature library in the knowledge-based engineering library.

8. A method as set forth inclaim 6 wherein the method includes the includes the steps of comparing the model of the instrument panel to a predetermined second criteria from the knowledge-based library, and varying the second parameter so that the model of the instrument panel meets the predetermined second criteria.

9. A method as set forth inclaim 1 wherein said knowledge-based engineering library is an electronic database of sub-libraries of data accessible by a user designing the instrument panel.

10. A method of knowledge-based engineering design of an instrument panel in a vehicle, wherein the method comprises the steps of:

defining a vehicle body model from a vehicle library within the knowledge-based engineering library;

defining an input parameter for a model of the instrument panel using the knowledge-based engineering library;

generating a model of the instrument panel using the input parameter and the vehicle body model;

comparing the model of the instrument panel to a predetermined criteria from the knowledge-based library;

modifying the input parameter so that the model of the instrument panel meets the predetermined initial criteria;

defining a second parameter for the model of the instrument panel using the knowledge-based engineering library

regenerating the model of the instrument panel using the second parameter;

comparing the model of the instrument panel to a second predetermined criteria from the knowledge-based engineering library; and

varying either one of the input parameter or the second parameter so that the model of the instrument panel meets the second predetermined criteria.

11. A method as set forth inclaim 10 wherein said step of defining an input parameter comprises defining a parameter describing characteristics of the vehicle from a product definition library within the knowledge-based engineering library.

12. A method as set forth inclaim 10 wherein said step of defining an input parameter comprises defining a component part to be included within the model of the instrument panel from a component part library within the knowledge-based engineering library.

13. A method as set forth inclaim 12 wherein the method includes the step of defining a component part parameter for the component part from the component part library.

14. A method as set forth inclaim 10, wherein the predetermined criteria comprises a knowledge-based engineering design rule from a knowledge-based engineering library.

15. A method as set forth inclaim 10, wherein the predetermined criteria comprises a computational fluid dynamics performance rule from a computational fluid dynamics library within the knowledge-based engineering library.

16. A method as set forth inclaim 10 wherein the predetermined criteria comprises a tooling feasibility rule from a tooling feasibility library within the knowledge-based engineering library.

17. A method as set forth inclaim 10 wherein the predetermined second criteria comprises a human factors analysis rule from a human factors library within the knowledge-based engineering library.

18. A method as set forth inclaim 10 wherein the second parameter is a characteristic of a fastener from a fastener library within the knowledge-based engineering library.

19. A method as set forth inclaim 10, wherein the method includes the step of comparing the fastener to a database of common fasteners within the fastener library.

20. A method as set forth inclaim 10 wherein the second parameter is a feature positioned on a surface of the instrument panel from a feature library within the knowledge-based engineering library.

21. A method as set forth inclaim 20 wherein the method includes the step of modifying the feature.

22. A method as set forth inclaim 10, wherein the method includes the step of interactively accessing a web-based library through the knowledge-based engineering library.

23. A method of knowledge-based engineering design of an instrument panel for a vehicle, the method comprising the steps of:

selecting a vehicle body model for the vehicle from a knowledge-based engineering library stored in a memory of a computer system;

defining an input parameter for a model of the instrument panel from a knowledge-based engineering library stored in a memory of a computer system;

defining a human factors parameter of the instrument panel from a human factors library within the knowledge-based engineering library;

generating the model of the instrument panel using the input parameter, the human factors parameter and the parametric vehicle body model;

analyzing the model of the instrument panel using a human factors engineering method;

comparing the analysis of the model of the instrument panel to a predetermined human factors criteria from the knowledge-based library; and

modifying the human factors parameter so that the model of the instrument panel meets the predetermined human factors criteria.

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